Product Safety - Daytime Running Lamp (DRL)/Turn Signal Bulb Replacement and DRL Jumper Kit Installation

THE CANADIAN VERSION OF THIS RECALL FOLLOWS THIS VERSION.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letter, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

Saturn has decided that a defect relating to motor vehicle safety exists in certain 2003-2004 model year Saturn ION sedans. These vehicles have a condition in which the turn signal lamp and daytime running lamp (DRL) on either front side can stop working because of loss of contact between the bulb and socket. If a front turn signal lamp is inoperative, others may react more slowly to a turning vehicle and a crash could occur.

To prevent this condition from occurring, Saturn will replace the DRL/turn signal bulb on both the left and right front side and inspect for and add a DRL jumper kit if not present. This service will be performed at no cost to the owner.

Certain 2003 and 2004 Saturn ION sedan vehicles within the following VIN range will require this recall:

3Z100001 - 3Z207807

4Z100063 - 4Z232317

Important: Retailers must verify recall involvement by running a National Vehicle History (NVH) prior to performing repairs. Not all vehicles within the above breakpoints may be involved. It is important to note that recall claims will only be paid on involved vehicles.

Owners of all involved vehicles will be notified of this recall by Saturn. (Refer to the owner letter included in this bulletin.)

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, (or are located in close proximity to your facility) is enclosed.

The listing contains:

The Facility VIN Listing is furnished to involved Retailers with the Product Safety Recall Bulletin.

Those Retailers not involved initially in this recall will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR RECALL 04095.

All unsold vehicles in Retailers’ possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before owners take possession of these vehicles.

Retailers are to service all vehicles subject to this recall at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the retailer listing, are to be contacted by the retailer. Arrangements are to be made to make the required correction according to the procedure contained in this bulletin. This could be done by mailing to such customers, a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your retail facility for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer’s address has recently changed, recall responsibility may be transferred by completing the following:

A copy of the Recall Vehicle Action Report, item #S03 2002RVAR, is included for your reference. Additional copies can be ordered from the Saturn Publications website at win.wallace.com/saturn. All changes to recall responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailer Service Policies & Procedures Manual, "Notifying Saturn of Vehicle Status Change."

Saturn Service Parts Operations (SSPO) will be shipping parts as they become available based on the affected vehicle population at your retail facility. Please do not order extra inventory of these parts or modify your existing stocking policies. Normal replenishment will continue to support your current stocking policy requirements.

*Important: Not all vehicles will require DRL jumper kit. Refer to Chart A and B in the Service Procedure section of this bulletin to determine which vehicles require the DRL jumper kit.

**Important: Only vehicles that require DRL jumper kit will require Threadlocker Loctite® 242.

Important: All material prices are retailer cost plus 40%.

***1 tube will service 100 vehicles. One tube $9.93/100 vehicles = $0.10 per vehicle.

Total Material Allowance is $0.10 per vehicle.

Retailers will scrap all replaced parts in a manner that ensures that they cannot be reused, remanufactured, or otherwise entered into the stream of commerce in the future.

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required. It is imperative that every effort is made to accommodate the affected owners. Additionally, priority should be given to customer vehicles over retail inventory vehicles. If you have any questions, please coordinate with the Saturn Customer Assistance Center to help ensure customer satisfaction.

DRL Jumper Kit and Park/Turn Signal/DRL Bulb Installation

1. Open the hood.



2. Pull up on headlamp assembly retaining pins. Remove the pins.
3. Position the headlamp assembly away from the vehicle to access the headlamp electrical connector.
4. Disconnect the forward lamp harness electrical connector from the headlamp assembly.
5. Remove the park/turn signal/DRL bulb access cover by rotating the cover counterclockwise.
6. Remove the park/turn signal/DRL bulb socket from the headlamp housing by rotating the socket counter clockwise.
7. Gently pull the park/turn signal/DRL bulb from the socket. Discard old bulb.



8. Install the new park/turn signal/DRL bulb (P/N 15233607) into the socket.
9. Install the park/turn signal/DRL bulb socket into the headlamp housing by rotating the socket clockwise.
10. Install the park/turn signal/DRL bulb access cover by rotating it clockwise.
11. Perform steps 2-10 for opposite headlamp assembly.

Important: The following charts will help determine if the vehicle needs the DRL jumper kit installed. Please note the VIN ranges associated with the two charts. Some vehicles produced after VIN 4Z160000 have already had the resistance added to the turn signal circuit within the main body wiring harness. These main body wiring harnesses are identified with pink tape on the passenger side tail lamp harness in the trunk.

•	For all 2003 model year vehicles and 2004 model year vehicles built prior to VIN 4Z160000 , refer to Chart A .

•	For 2004 model year vehicles built after and including VIN 4Z160000 , refer to Chart B .







Important: Perform steps 12-16 only if required in Chart A or Chart B .

12. Locate mounting hole for resistor (3) on both the passenger and driver side. This hole is on the vertical metal between the radiator core support and the frame rail, just outboard of the radiator/condenser assembly. (Driver’s side shown, passenger side in similar location.)

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.





Important: DRL jumper kit is to be installed on both the driver and passenger side headlamp wiring.

13. Install one resistor to each mounting hole using bolt, washer, and nut provided in DRL jumper kit, P/N 15146012. The washer needs to go between the resistor and the sheet metal surface to protect the resistor.
14. Prior to installation of each nut, apply Loctite® Threadlocker 242, P/N 21485277 (in Canada, P/N 10953489), or equivalent (GM Material Specification 998 5283) to exposed threads and tighten bolt.

Tighten
Tighten resistor retaining bolt 10 N·m (89 in-lbs).




15. Install DRL jumper harness connector into the resistor connector and the forward lamp harness connector on each side.
16. Secure jumper harness to vehicle using clip on connector to forward lamp harness on each side.

Important: Perform steps 17-21 on all vehicles.

17. Position each headlamp assembly in its respective vehicle opening and connect remaining headlamp wiring harness connector to connector on the headlamp assembly.



18. Install each headlamp assembly into its respective headlamp bracket and install headlamp assembly retaining pins by pushing down on the pins.
19. Clear diagnostic trouble codes (DTCs) from body control module (BCM) using Tech 2 scan tool.
20. Activate left and right turn signal to verify proper operation.
21. Close the hood.

1. To receive credit for replacing the park/turn signal/DRL bulb on both the left and right front side and inspect for and add a DRL jumper kit, if required, submit a claim with the information below:

Important: To claim Loctite® Threadlocker 242, it will be necessary to sell these materials to the CSO as "material" using net item code "M" per the Parts Information chart in this bulletin ($0.10 per claim when DRL jumper kit is installed).

2. To receive credit for loaner/rental car cost or other goodwill expenses, submit a claim with the information below:

3. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type, and VC case type. Contact your field representative if you need assistance.

4. All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation Manual for details on Product Safety Recall Claim Submission.

5. Customer Reimbursement Claims - Special Attention Required

A. Customer reimbursement claims must have the date of the DRL/Turn Signal Bulb prior replacement entered into the "repair date" field of the CSO in the "Labor Detail/Comments" screen.

B. Customer reimbursement claims must have the mileage of the prior repair of the DRL/Turn Signal Bulb entered on the "Service Order Hub" screen in the "miles in" field.

C. Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer.

D. Customer reimbursement claims must be submitted on a different CSO than the Recall repair. This is because the repair date and mileage differ between the two repairs.

November, 2004

Dear Saturn Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Saturn has decided that a defect relating to motor vehicle safety exists in certain 2003-2004 model year Saturn ION sedans. These vehicles have a condition in which the turn signal lamp and daytime running lamp (DRL) on either front side can stop working because of loss of contact between the bulb and socket. If a front turn signal lamp is inoperative, others may react more slowly to a turning vehicle and a crash could occur.

What Saturn will do: To prevent this condition from occurring, Saturn will replace the DRL/turn signal bulb on both the left and right front side and inspect for and add a DRL jumper kit if not present. This service will be performed at no cost to the owner.

Unfortunately, this situation presents a unique challenge for Saturn because our parts availability is not sufficient to perform replacements at this time. We are currently working with our parts supplier to produce quality parts in a timely manner. We anticipate having a sufficient quantity of parts in February, 2005.

As parts become available, Saturn will re-contact you. At that time you should contact your Saturn Retailer to schedule an appointment for the repair to your vehicle.

What you should do: It is not necessary to take your vehicle to a Saturn Retailer for repair at this time. However, if a DRL/turn signal bulb fails to illuminate, the turn signal indicator on the dash will flash at approximately twice its normal rate. If your vehicle exhibits this condition, contact your retailer to have the repairs completed.

Your Retailer is prepared to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. If your car is provided to the Retailer on the agreed service date and the condition is not remedied on that date, or within a reasonable time, please contact the Saturn Customer Assistance Center at 1-800-972-8876, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Saturn Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 7th St., SW, Washington, DC 20590, or call 1-888-327-4236.

Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition.

When parts become available, it will still be necessary to have this recall repair performed on your vehicle, even if you have had previous repairs to the DRL/turn signal bulbs.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

We sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of enjoyable driving.

Sincerely,

Saturn

04095

If you paid to have this recall condition corrected before November 2004, you may be eligible to receive reimbursement.

Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Saturn retailer.

Submitting a recall reimbursement claim directly to your Saturn retailer may expedite processing, however; if you choose, you may file your claim through the Saturn Customer Assistance Center. Your claim will be acted upon within 60 days of receipt.

If your claim is:

Please follow the instructions on the Claim Form provided in this bulletin to file a claim for reimbursement. If you have any questions or need assistance, please contact your Saturn retailer or the Saturn Customer Assistance at 1-800-972-8876, or for the hearing impaired, 1-800-833-6000.

MODELS: 2003-2004 SATURN ION SEDAN VEHICLES

ATTENTION: General Motors of Canada Ltd. Saturn Retailers

Saturn has decided that a defect relating to motor vehicle safety exists in certain 2003-2004 model year Saturn ION sedans. These vehicles have a condition in which the turn signal lamp and daytime running lamp (DRL) on either front side can stop working because of loss of contact between the bulb and socket. If a front turn signal lamp is inoperative, others may react more slowly to a turning vehicle and a crash could occur.

To prevent this condition from occurring, Saturn will replace the DRL/turn signal bulb on both the left and right front side and inspect for and add a DRL jumper kit if not present. This service will be performed at no cost to the owner.

Involved are certain 2003-2004 Saturn ION Sedan vehicles built within these VIN breakpoints:

Important: Retailers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For retailers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved retailers. Retailers that have no involved vehicles currently assigned, will not receive a Campaign Initiation Detail Report.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

*Important: Not all vehicles will require DRL jumper kit. Refer to Chart A and B in the service procedure of this bulletin to determine which vehicles require the DRL jumper kit.

**Important: Only vehicles that require DRL jumper kit will require Threadlocker Loctite® 242.

***1 tube will service 100 vehicles. One tube $3.99/100 vehicles = $0.04

DRL Jumper Kit and Park/Turn Signal/DRL Bulb Installation

1. Open the hood.



2. Pull up on headlamp assembly retaining pins. Remove the pins.
3. Position the headlamp assembly away from the vehicle to access the headlamp electrical connector.
4. Disconnect the forward lamp harness electrical connector from the headlamp assembly.
5. Remove the park/turn signal/DRL bulb access cover by rotating the cover counterclockwise.
6. Remove the park/turn signal/DRL bulb socket from the headlamp housing by rotating the socket counter clockwise.
7. Gently pull the park/turn signal/DRL bulb from the socket. Discard old bulb.



8. Install the new park/turn signal/DRL bulb (P/N 15233607) into the socket.
9. Install the park/turn signal/DRL bulb socket into the headlamp housing by rotating the socket clockwise.
10. Install the park/turn signal/DRL bulb access cover by rotating it clockwise.
11. Perform steps 2-10 for opposite headlamp assembly.

Important: The following charts will help determine if the vehicle needs the DRL jumper kit installed. Please note the VIN ranges associated with the two charts. Some vehicles produced after VIN 4Z160000 have already had the resistance added to the turn signal circuit within the main body wiring harness. These main body wiring harnesses are identified with pink tape on the passenger side tail lamp harness in the trunk.

•	For all 2003 model year vehicles and 2004 model year vehicles built prior to VIN 4Z160000 , refer to Chart A .

•	For 2004 model year vehicles built after and including VIN 4Z160000 , refer to Chart B .







Important: Perform steps 12-16 only if required in Chart A or Chart B .

12. Locate mounting hole for resistor (3) on both the passenger and driver side. This hole is on the vertical metal between the radiator core support and the frame rail, just outboard of the radiator/condenser assembly. (Driver’s side shown, passenger side in similar location.)

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.





Important: DRL jumper kit is to be installed on both the driver and passenger side headlamp wiring.

13. Install one resistor to each mounting hole using bolt, washer, and nut provided in DRL jumper kit, P/N 15146012. The washer needs to go between the resistor and the sheet metal surface to protect the resistor.
14. Prior to installation of each nut, apply Loctite® Threadlocker 242, P/N 10953489, or equivalent (GM Material Specification 998 5283) to exposed threads and tighten bolt.

Tighten
Tighten resistor retaining bolt 10 N·m (89 in-lbs).




15. Install DRL jumper harness connector into the resistor connector and the forward lamp harness connector on each side.
16. Secure jumper harness to vehicle using clip on connector to forward lamp harness on each side.

Important: Perform steps 17-21 on all vehicles.

17. Position each headlamp assembly in its respective vehicle opening and connect remaining headlamp wiring harness connector to connector on the headlamp assembly.



18. Install each headlamp assembly into its respective headlamp bracket and install headlamp assembly retaining pins by pushing down on the pins.
19. Clear diagnostic trouble codes (DTCs) from body control module (BCM) using Tech 2 scan tool.
20. Activate left and right turn signal to verify proper operation.
21. Close the hood.

Submit a Product Recall Claim with the information indicated below:

* For Recall Administrative Allowance, add 0.1 hours to the "Labour Hours".

** The "Parts Allowance" should be the sum total of the current GMSPO Retailer Net price plus applicable mark-up for parts needed to complete this repair.

*** The amount identified in the "Net Item" column should represent the customer reimbursement amount.

Refer to the General Motors Claims Processing Manual for details on Product Recall Claim Submission.

Customer requests for reimbursement of previously paid repairs to replace DRL/Turn Signal Bulb, are to be submitted prior to or by February 28, 2006.

If the work was done by someone other than a Saturn retail facility, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a Saturn retail facility.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

All unsold new vehicles in Retailers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles.

Retailers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the Retailer listing, are to be contacted by the Retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your retail facility for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear Saturn Owner:

Saturn has decided that a defect relating to motor vehicle safety exists in certain 2003-2004 model year Saturn ION sedans. These vehicles have a condition in which the turn signal lamp and daytime running lamp (DRL) on either front side can stop working because of loss of contact between the bulb and socket. If a front turn signal lamp is inoperative, others may react more slowly to a turning vehicle and a crash could occur.

To prevent this condition from occurring, Saturn will replace the DRL/turn signal bulb on both the left and right front side and inspect for and add a DRL jumper kit if not present. This service will be performed for you at no charge.

You may be contacted by a Retailer other than the Retailer who sold or is currently servicing your vehicle. Please be advised that you may take your vehicle to the Saturn facility of your choice to have the recall service work completed. Please contact your Saturn Retailer as soon as possible to arrange a service date. This letter identifies your vehicle. Presentation of this letter to your Retailer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

If you have paid to have this recall condition corrected prior to this notification, and you have not received reimbursement under a Vehicle Service Contract, you should contact your retailer to seek reimbursement. Please provide your retailer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your retailer by February 28, 2006. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Saturn Retailer.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

Customer Support Department

04095

/ks